Apparatus and method of forming barbs on a suture

ABSTRACT

A barbed suture is provided. The barbed suture includes an elongate body and at least one barb extending from the elongate body. The elongate body defines a recess adjacent the at least one barb. Also provided is a method of making a barbed suture. The method includes the steps of providing a suture nest and a punch apparatus configured for operable engagement with the suture nest, loading a suture through the suture nest, engaging the punch apparatus with the suture nest, and disengaging the punch apparatus with the suture nest.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of and priority to U.S.Provisional Application Ser. No. 61/480,658, filed Apr. 29, 2011, thecontent of which is incorporated by reference herein in its entirety.

BACKGROUND

Technical Field

The present disclosure relates to apparatus and methods for formingbarbs on sutures. More particularly, the present disclosure relates toapparatus and methods of forming barbs on sutures using heat staking.

Background of Related Art

Barbed sutures are generally made of the same materials as conventionalsutures and offer several advantages for closing wounds compared withconventional sutures. A barbed suture includes an elongate body that hasone or more spaced barbs which project outward from the surface of thesuture body along the body length. The barbs are arranged to allowpassage of the barbed suture in one direction through tissue but resistmovement of the barbed suture in the opposite direction. Thus, oneadvantage of barbed sutures has been the provision of a non-slipattribute.

Barbed sutures are used in countless procedures. The number of barbscalled for on a particular suture may be influenced by the size of thewound and the strength required to hold the wound closed. Like aconventional suture, a barbed suture may be inserted into tissue using asurgical needle.

In some circumstances, a specific configuration of barbs on the exteriorsurface of the suture is preferred to achieve optimal wound closureholding for the particular wound. However, in other circumstances, wherethe wound or tissue repair needed is relatively small, a reduced numberof barbs may be desired. In other circumstances, a bi-directional barbedsuture is desirable where the barbs over a portion of the suture permitpassing of the suture in one direction and barbs over another portion ofthe suture permit passing of the suture in a second direction to performa tight closing stitch.

Various methods of forming barbs on sutures have been proposed such asmechanical cutting, laser cutting, injection molding, extrusion and thelike. However, such methods may be difficult or costly to achieve thedesired result with respect to getting the arrangement of barbs in aconfiguration needed for the appropriate procedure and for doing so inan efficient cost effective manner.

Accordingly, there is a continuing need for methods of forming barbs ona suture that are less difficult, more effective and/or economical.There is also a continuing need for methods which are able to vary thesize, the number, the location and/or the depth of the barbs.

SUMMARY

A system for forming one or more barbs on a length of suture isprovided. The system includes a suture nest and a punch apparatus. Thesuture nest defines a longitudinal passage configured for receipt of alength of suture. The suture nest includes at least one recess formedalong the longitudinal passage and at least one opening corresponding tothe at least one recess. The punch apparatus includes at least one punchmember corresponding to the at least one opening in the suture nest. Theat least one punch member is configured to be selectively receivedwithin the at least one opening in the suture nest.

In one embodiment, the suture nest includes a plurality of recesses anda plurality of corresponding openings. The punch apparatus may include aplurality of punch members corresponding to the plurality of openings inthe suture nest. At least one of the punch apparatus and the nest may beselectively movable relative to the other. The suture nest may includefirst and second nest halves and at least one recess may be formed inone of the first and second nest halves. At least one openingcorresponding to the at least one recess may be formed on the other ofthe first and second nest halves.

A suture forming nest is also provided. The suture forming nest includesa first nest half defining a first longitudinal groove and a second nesthalf defining a second longitudinal groove corresponding to the firstlongitudinal groove. The first nest half further defines at least afirst recess formed along the longitudinal groove. The second nest halffurther defines at least a first opening extending therethroughcorresponding to the at least first recess of the first nest half.

In one embodiment, the first and second nest halves each include aninner surface configured to be in contact during a suture formingprocess. The first and second longitudinal grooves may form alongitudinal passage for receiving a suture when the first and secondinner surfaces of the first and second nest halves are in contact. Thefirst nest half may include a plurality of recesses formed along thefirst longitudinal groove. The plurality of recesses may be formed onalternating sides of the first longitudinal groove. The second nest halfmay include a plurality of openings formed along the first longitudinalgroove. The plurality of openings may be formed on alternating sides ofthe second longitudinal groove. The at least one recess may form one ofa pointed barb and a rounded barb. The second nest half may beconfigured to engage a punch.

Also provided is a punch device for use with a suture forming nest. Theapparatus includes a base and at least one punch assembly extending fromthe base. The at least one punch assembly includes a base member and apunch member. The punch member may be configured for reception within anopening of the suture nest. The base member may be selectivelyextendable relative to the base and/or the base member. The distal endof the punch member may be configured to engage a suture. The punchdevice may further include a mechanism for heating the at least onepunch member.

Additionally, a barbed suture is provided. The barbed suture includes anelongate body and at least one barb extending from the elongate body,wherein the elongate body defines a recess adjacent the at least onebarb. In one embodiment, the elongate body includes a plurality ofbarbs. The barbed suture may further include one or more ridgesextending about the recess defined in the elongate body. The pluralityof ridges corresponds to each of the plurality of barbs. The recessesadjacent the at least one barb may be oriented in the same direction asthe at least one barb. The recess may be substantially oval.

A method of making a barbed suture is also provided. The method includesthe steps of providing a suture nest and a punch apparatus configuredfor operable engagement with the suture nest, loading a suture throughthe suture nest, engaging the punch apparatus with the suture nest, anddisengaging the punch apparatus with the suture nest. The suture nestmay include first and second suture halves. The first nest half maydefine a first longitudinal groove and at least a first recess formedalong the longitudinal groove. The second nest half may define a secondlongitudinal groove corresponding to the first longitudinal groove andat least a first opening extending therethrough corresponding to the atleast first recess of the first nest half. The first and secondlongitudinal grooves may form an elongate passage through the nest whenthe first and second nest halves are engaged.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present disclosure will be described hereinbelow with reference to the figures wherein:

FIG. 1A is a perspective view of an embodiment of a barbed suture formedof a monofilament thread in accordance with the present disclosure;

FIG. 1B is a perspective view of another embodiment of a barbed sutureformed of a multifilament braided thread in accordance with the presentdisclosure;

FIG. 1C is a cross-sectional view of the barbed suture of FIG. 1A;

FIGS. 2A-2G are ends views of sutures having alternative cross-sectionalgeometries, including circular (FIG. 2A), elliptical (FIG. 2B), square(FIG. 2C), star-shaped (FIG. 2D), octagonal (FIG. 2E), rectangular (FIG.2F), and planar (FIG. 2G);

FIG. 3 is a perspective view of a barbed suture forming nest accordingto an embodiment of the present disclosure;

FIG. 4A is a front side view of a first nest half of the barbed sutureforming nest of FIG. 3;

FIG. 4B is a back side view of the first nest half of FIG. 4A;

FIGS. 5A and 5B are enlarged sectional views of nest halves according toalternative embodiments of the present disclosure;

FIG. 6A is a front side view of a second nest half of the barbed sutureforming nest of FIG. 3;

FIG. 6B is a back side view of the second nest halve of FIG. 6A;

FIG. 7 is a front view of a punch for use with the barbed suture formingnest of FIG. 3;

FIG. 8 is a side view of the punch of FIG. 7;

FIG. 9 is a cross-sectional view of the barbed suture forming nest ofFIG. 3 taken along plane 9 of FIG. 3;

FIG. 10 is a cross-sectional view of the barbed suture forming nest ofFIG. 9, including a length of suture received therein;

FIG. 11 is a cross-sectional view of the barbed suture forming nest andsuture of FIG. 10, including a punch assembly being operably engagedtherewith;

FIG. 12 is a cross-sectional view of the barbed suture forming nest andsuture of FIG. 11, including the punch assembly being operablydisengaged therewith;

FIG. 13 is a cross-sectional view of a barbed suture forming nestaccording to an alternative embodiment of the present disclosure, in anopen position and including a length of suture received therethrough;

FIG. 14 is a cross-sectional view of the barbed suture forming nest ofFIG. 13, in a closed position;

FIG. 15 is a cross-sectional view of a barbed suture forming nestaccording to another embodiment of the present disclosure, in an openposition and including a length of suture received therethrough;

FIG. 16 is a cross-sectional view of the barbed suture forming nest ofFIG. 15, in a closed position, including a pair of punch assembliesoperably engaged therewith;

FIG. 17 is a cross-sectional view of a barb forming nest according toyet another embodiment of the present disclosure;

FIG. 18 is a cross-sectional view of the barb forming nest of FIG. 17including a suture received therein and prior to barb formation; and

FIG. 19 is a cross-sectional view of the barb forming nest and suture ofFIG. 17, post barb formation.

DETAILED DESCRIPTION

Disclosed herein are an apparatus, system and method for forming asuture having at least one barb formed along the length thereof.Referring now in detail to the drawings in which like reference numeralsare applied to like elements in the various views, FIGS. 1A and 1Billustrate a length of suture 10 having an elongate body 12 and aplurality of barbs 14 formed therefrom. Suture 10 has a proximal end 10a and distal end 10 b. Either or both of proximal and distal ends 10 a,10 b may include a needle (not shown). As shown, barbs 14 are formedprojecting outward from elongate body 12 of suture 10 in a firstdirection, however, it is envisioned that barbs 14 may project outwardlyin a first direction along a first portion of suture 10 and a secondlength of barbs 14 may project outwardly in a second direction along asecond portion of suture 10, thereby forming a bi-directional barbedsuture.

With reference still to FIGS. 1A and 1B, barbs 14 form an angle “α”(FIG. 1A) of less than ninety degrees (90°) between barbs 14 andelongate body 12. Each of barbs 14 includes a cavity or recess 15 whichis at least partially disposed along elongate body 12. As shown, eachrecess 15 is defined by a ridge 16 (FIG. 1C). Ridges 16 are formed froma portion of elongate body 12 and have an increased thickness and/ordensity. Ridges 16 are created as part of the barb forming process.Although shown including ridges 16, it is envisioned that elongate body12 may define one or more recesses 15 formed without ridges 16.Alternatively, it is envisioned that elongate body 12 may define arecess formed with multiple ridges 16, 16 a. (See FIG. 1C, shown inphantom). Recesses 15 and/or ridges 16 may be configured to addstructural strength to barbs 14 and/or elongate body 12. As seen inFIGS. 1A and 1B, recesses 15 are oriented in the same direction as barbs14.

As shown in FIG. 1A, suture 10 is formed of a monofilament thread. Withreference to FIG. 1B, as shown, suture 10 is formed of braided threads.The braiding may be done by any method within the purview of thoseskilled in the art. The filaments and/or fibers used for forming suture10 may be formed using any technique within the purview of those skilledin the art, such as, for example, extrusion and/or molding. In someembodiments, the suture may include a yarn made of more than onefilament. The filament or filaments may contain multiple strands of thesame or different materials. Where suture 10 is made of multiplefilaments, suture 10 may be made using any known technique such as, forexample, braiding, weaving or knitting. The filaments may also becombined to produce a non-woven suture. The filaments themselves may bedrawn, oriented, crinkled, twisted, commingled or air entangled to formyarns as part of the suture forming process. As will become apparentfrom the following disclosure, certain aspects of the present disclosureare especially well suited for use with braided and/or multifilamentsutures as the barb forming process may operate to join or secure themultiple threads with each other.

Suture 10 may be formed of degradable materials, non-degradablematerials, and combinations thereof. More particularly, suture 10 may beformed of a degradable material selected from the group consisting ofpolyesters, polyorthoesters, polymer drugs, polydroxybutyrates,proteins, carbonates, homopolymers thereof, copolymers thereof, andcombinations thereof. In other embodiments, suitable degradablematerials which may be utilized to form suture 10 include naturalcollagenous materials or synthetic resins.

Suitable non-degradable materials which may be utilized to form suture10 include polyolefins, such as polyethylene and polypropylene;copolymers of polyethylene and polypropylene, and blends of polyethyleneand polypropylene; polyamides (such as nylon); polyamines; polyimines;polyesters such as polyethylene terephthalate; polytetrafluoroethylene;polyether-esters such as polybutester; polytetramethylene ether glycol;1,4-butanediol; polyurethanes; and combinations thereof. Thepolypropylene may be isotactic polypropylene or a mixture of isotacticand syndiotactic or atactic polypropylene.

As shown in FIGS. 1A and 1B, suture 10 is circular in cross-sectionalgeometry, however, the cross-sectional geometry of suture 10 may be ofany suitable shape. For example, with reference to FIGS. 2A-2G, thecross-sectional geometry of suture 10 may include, circular (FIG. 2A),elliptical (FIG. 2B), square (FIG. 2C), star-shaped (FIG. 2D), octagonal(FIG. 2E), rectangular (FIG. 2F), and planar (FIG. 2G).

With reference now to FIG. 3, an embodiment of an apparatus for formingbarbs 14 on suture 10 (FIGS. 1A and 1B) is shown generally as sutureforming nest 100. Suture forming nest 100 includes first and second nesthalves 110, 120. First and second nest halves 110, 120 cooperate to forma cavity 101 configured for receipt of a length of suture 10 therein.

With reference now to FIGS. 3, 4A and 4B, first nest half 110 of sutureforming nest 100 defines a longitudinal groove 111 along an innersurface 112. Longitudinal groove 111 is configured to receive elongatebody 12 of suture 10. A plurality of barb-shaped recesses 113 are formedin inner surface 112 along the length of longitudinal groove 111. Asshown, recesses 113 are formed along first and second sides of groove111 in an alternating pattern. It is envisioned, however, that recesses113 may be formed in inner surface 112 along only one side of groove111. It is further envisioned that first nest half 110 may include onlya single recess 113 formed in inner surface 112. As shown, recesses 113form substantially triangular cut-outs. Turning briefly to FIGS. 5A and5B, first nest half 110 may instead define sharpened recesses 113 a(FIG. 5A) for forming a pointed barb or rounded recesses 113 b (FIG. 5B)for forming a smooth barb. In one embodiment, nest half 110 may definerecesses 113 having one or more different configurations. In anotherembodiment, recesses 113 may not only differ in shape, but also in size.

With reference now to FIGS. 3, 6A and 6B, second nest half 120 defines alongitudinal groove 121 along an inner surface 122 thereof. Longitudinalgroove 121 is configured to receive elongate body 12 of suture 10 andcorresponds to longitudinal groove 111 of first nest half 110.Longitudinal grooves 111, 121 cooperate when inner surfaces 112, 122 ofrespective first and second halves 110, 120 are in contact with eachother to form passage 101 through barb forming nest 100. Second nesthalf 120 further defines a plurality of openings 123. Openings 123extend through second nest half 120. Each opening 123 correspond to arecess 113 formed in first nest half 110. Each of openings 123 isconfigured to receive a distal end of a punch member 156 (FIG. 8). Aswill be discussed in further detail below, punch member 156 is receivedthrough openings 123 to form barb 14 in elongate body 12 of suture 10(FIG. 1). As shown, openings 123 define slots having a substantiallyoval cross-section configured to receive a distal end 156 b of punchmember 156 having a substantially oval cross-section. Openings 123 areoriented such that a portion of distal end 156 b of punch member 156engages a portion of elongate body 12 of suture 10.

With reference to FIGS. 7 and 8, an apparatus for use with sutureforming nest 100 is shown generally as punch 150. Punch 150 includes abase 151 and a plurality of punch assemblies 152 operably connected tobase 151. The configuration of punch assemblies 152 corresponds toopenings 123 of suture forming nest 100. Punch assemblies 152 eachinclude a base 154 and a punch member 156 extending from base 154. Punchmember 156 includes a rounded distal end 156 b. Although shown having asubstantially orthogonal distal surface 157, it is envisioned thatdistal surface 157 of punch member 156 may be angled. Angling of distalsurface 157 may facilitate movement of the suture material duringforming of barbs 14 and/or may facilitate the forming of recess 15 (FIG.1A) on elongate body 12 of suture 10. Although not shown, distal surface157 of punch member 156 may be contoured or otherwise configured tofacilitate forming of one or more ridges 15 on elongate body 12 ofsuture 10. Punch member 156 is of sufficient length to extend throughopenings 123 of second nest half 120 such that distal end 156 b of punchmember 156 engages elongate body 12 of suture 10. In one embodiment,punch member 156 is of a length such that a distal surface 155 of base154 engages an outer surface of second nest half 120. In this manner,distal surface 155 of base 154 acts as a stop to prevent over insertionof punch member 156 within opening 123.

Base members 154 and/or punch members 156 may be configured forselective rotation about a longitudinal axis “X” thereof (FIG. 8). Inthis manner, punch members 156 may be reoriented to correspond withalternatively oriented openings in alternative suture forming nests.Base members 154 may also be configured for selective removal from punch150. In this manner, one or more punch assemblies 152 may be removedsuch that punch 150 may be used with a suture forming nest having fewerthan five (5) openings. Additionally, selective removal of base members154 permits replacing punch members 156 in the event of damage to punchmember 156, or to replace punch members 156 with alternativelyconfigured punch members (not shown) for use with alternatively formedopenings.

With reference still to FIGS. 7 and 8, in one embodiment, base members154 are configured to selectively extend from base 151 of punch 150. Inthis manner, punch 150 may be fixed relative to suture forming nest 100and positioned such that punch members 156 align with openings 123 insecond nest half 110. Upon advancement of base members 154 relative tobase 151, as indicated by arrows “A” (FIG. 8), punch members 156 arereceived in openings 123 (FIG. 6A) of second nest half 120.Alternatively, base members 154 may be fixed relative to base 151, whilebase 151 is configured to be moved relative to suture forming nest 100.In this manner, upon advancement of base 151 relative to nest 100, asindicated by arrows “B” (FIG. 8), punch members 156 are received inopenings 123 of second nest half 120. Regardless of whether either orboth of base 151 and/or base members 154 are advanced, retraction ofrespective base members 154 and/or base 151, causes retraction of punchmembers 156 from within openings 123 of second nest half 120.

Still referring to FIGS. 7 and 8, base 151 of punch 150 includes amechanism 158 for heating each of punch members 156. Mechanism 158 mayinclude a heating element (not shown) or any other suitable method forheating punch member 156, i.e., laser beams, electric current flowingthrough resistors, inductive heating. Alternatively, base 151 mayinclude an ultrasonic device (not shown) for ultrasonically oscillatingpunch members 156. In certain embodiments, the ultrasonic device createsfriction between elongate body 12 of suture 10 (FIG. 1A) and punchmember 156, thereby causing that portion of elongate body 12 in contactwith punch member 156 to soften or become pliable. In yet otherembodiments, punch members 156 and/or elongate body 12 may be treatedwith a solvent or other chemical to soften or make pliable the materialforming elongate body 12 in order to facilitate molding of barbs 14.

The use of suture forming nest 100 will now be described with referenceto FIGS. 9-12. Referring initially to FIG. 9, inner surfaces 112, 122 offirst and second nest halves 110, 120 are shown in contact to formelongated passage 101. A suture 10 may then be loaded throughlongitudinal passage 101. Alternatively, either or both of first andsecond nest halves 110, 120 may be approximated away from the other nesthalf, as indicated by arrows “C”, such that a suture may be loadedtherein. Turning briefly to FIG. 10, suture 10 is shown positionedwithin passage 101 of suture nest 100.

With reference now to FIG. 11, once suture 10 is positioned withinelongate passage 101 of barb forming nest 100, punch 150 (FIG. 7) areactivated and punch members 156 thereof are inserted throughcorresponding openings 123 in second nest half 120 of nest 100. Punchmembers 156 may be inserted into openings 123 individually orsimultaneously. As discussed above, punch 150 includes a plurality ofpunch members 156 corresponding in size and location with openings 123of second nest half 120.

With reference still to FIG. 11, as discussed above, punch member 156 isadvanced, as indicated by arrow “D”, such that distal end 156 b thereofengages a portion of elongate body 12 of suture 10. Continuedadvancement of punch member 156 relative to suture 10 causes localizedsoftening or melting of elongate body 12 of suture 10 and displacementof the softened/melted material into recess 113 of first nest half 110.As discussed above, distal surface 157 of punch member 156 may be angledto facilitate flow of the melted material into recess 113. In oneembodiment, and as shown, distal surface 155 of base member 154 isconfigured to engage second nest half 120 of suture forming nest 100upon complete reception of punch member 156 within opening 123, therebyacting as a stop to prevent over-insertion of punch members 156 intoopenings 123. Alternatively, the mechanism for advancing and retractingeither or both of base members 154 and base 151 may include a stopfeature to prevent over-insertion of punch members 156 within openings123.

Once punch member 156 has been appropriately advanced, heating mechanism158 may be deactivated to permit cooling of punch member 156. In oneembodiment, punch assemblies 152 include a heat sink (not shown) forassisting in cooling punch member 156. With reference now to FIG. 12,upon sufficient cooling of punch member 156, punch member 156 isretracted away from elongate body 12 of suture 10, as indicated by arrow“E”, such that distal end 156 b of punch member 156 disengages fromelongate body 12 of suture 10.

Depending on the configuration of suture forming nest 100 and thedesired number and configuration of barbs 14, suture 10 may be advancelongitudinally relative to suture forming nest 100 to receive a smoothlength of suture 10 therein. Suture 10 may also be rotated along thelongitudinal axis to radially offset the subsequently formed barbs fromthe previously formed barbs. Alternatively, suture forming nest 100 maybe configured to accommodate an entire length of suture 10 such thatbarbs 14 may be formed simultaneously or without moving suture 10. Inanother embodiment, suture 10 is removed from within elongate passage101 of nest 100 and rotated one-hundred eighty degrees (180°) to formbarbs extending opposite the first barbs. In this manner, abi-directional barbed suture may be formed. The barb forming process maybe repeated along the length of suture 10.

It is envisioned that suture forming nest 100 may be modified to formbarbs of various configuration. Barbs 14 may be arranged in any suitablepattern, for example, helical, linear, or randomly spaced. The patternmay be symmetrical or asymmetrical. The number, configuration, spacingand surface area of barbs 14 may vary depending upon the tissue in whichthe suture is used, as well as the composition and geometry of thematerial utilized to form suture 10. Additionally, the proportions ofbarbs 14 may remain relatively constant while the overall length ofbarbs 14 and the spacing of barbs 14 may be determined by the tissuebeing connected. For example, if suture 10 is to be used to connect theedges of a wound in skin or tendon, barbs 14 may be made relativelyshort and more rigid to facilitate entry into this rather firm tissue.Alternatively, if suture 10 is intended for use in fatty tissue, whichis relatively soft, barbs 14 may be made longer and spaced further apartto increase the ability of the suture to grip the soft tissue.

The surface area of barbs 14 may also vary. For example, fuller-tippedbarbs may be made of varying sizes designed for specific surgicalapplications. For joining fat and relatively soft tissues, larger barbsmay be desired, whereas smaller barbs may be more suitable forcollagen-dense tissues. In some embodiments, a combination of large andsmall barbs within the same structure may be beneficial, for example,when a suture is used in tissue repair with differing layer structures.The use of the combination of large and small barbs with the same suturewherein the barb sizes are customized for each tissue layer may maximizethe anchoring properties of the suture. In particular embodiments, asingle directional suture may have both large and small barbs; in otherembodiments a bi-directional suture may have both large and small barbs.The barbs formed may include geometrical shapes such as round,triangular, square, oblique, elliptical, octagonal, rectangular, andflat.

With reference now to FIGS. 13 and 14, an alternative embodiment of anapparatus for forming barbs 14 on suture 10 (FIGS. 1A and 1B) is showngenerally as suture forming nest 200. Suture forming nest 200 issubstantially similar to suture forming nest 100 described hereinabove,and therefore will only be described as relates to the differencestherebetween.

Still referring to FIGS. 13 and 14, suture forming nest 200 includes afirst nest half 210 defining a longitudinal groove 211 and a second nesthalf 202 defining a longitudinal groove 221. First and second nesthalves 210, 220 correspond to form elongate passage 201. As seen in FIG.13, elongate passage 201 is configured to receive elongate body 12 ofsuture 10 having a diameter that is larger than the diameter of elongatepassage 201. Alternatively, elongate body 12 of suture 10 may have adifferent cross-sectional configuration than the cross-sectionalconfiguration of elongate passage 201. As shown, elongate body 12 ofsuture 10 includes a substantially circular cross-sectionalconfiguration while elongate passage 201 includes a substantially ovalcross-sectional configuration. Although shown having a substantiallyoval cross-sectional configuration, it is envisioned that elongatepassage 201 may have other cross-sectional shapes. For example, elongatepassage 201 may instead have a diamond-shaped cross-sectionalconfiguration. First nest half 210 further defines at least one recess213 for forming a barb 14 on suture 10 (FIG. 1A). Second nest half 220further defines at least one opening 223 corresponding to barb formingrecess 213. As with opening 123 of second nest half 120, opening 223 isconfigured to receive punch member 156.

Turning to FIG. 14, first and second nest halves 210, 220 are configuredsuch that, when suture forming nest 200 is closed about elongate body 12of suture 10, elongate body 12 is deformed in a manner that pinches aportion of elongate body 12 towards recess 213. In this manner, firstand second nest halves 210, 220 facilitate the forming of a barb 14 onelongate body 12 of suture 10.

With reference now to FIGS. 15 and 16, another embodiment of anapparatus for forming barbs on elongate body 12 of a suture is showngenerally as suture forming nest 300. Suture forming nest 300 issubstantially similar to suture forming nests 100 and 200 describedhereinabove, and therefore, will only be described as relates to thedifferences therebetween.

Suture forming nest 300 includes first and second nest halves 310, 320.Each of first and second nest halves 310, 320 define a longitudinalgroove 311, 321, respectively, which correspond to form an elongatepassage 301. Each of first and second nest halves 310, 320 furtherdefine openings 313, 323, respectively. Openings 313, 323 are alignedwith one another and are each configured to receive a punch member 156.As seen in FIG. 16, first and second nest halves 310, 320 are configuredto simultaneously receive punch members 156 through respective openings313, 323 to cause the formation of a barb on elongate body 12 of thesuture.

With reference now to FIGS. 17-19, yet another embodiment of a sutureforming nest according to the present disclosure is shown generally assuture forming nest 400. Barb forming nest 400 is similar to sutureforming nests 100, 200 and 300 described hereinabove, and therefore,will only be described as relates to the differences therebetween.

With reference still to FIGS. 17-19, suture forming nest 200 includesfirst and second nest halves 410, 420. Each of barb forming nests 410,420 include an inner surface 412, 422 defining a longitudinal groove411, 421, respectively. Longitudinal grooves 411, 421 cooperate to forman elongate passage 401 between first and second nest halves 410, 420when inner surfaces 412, 422 thereof are in contact. First nest half 410further defines at least one recess 413 extending from longitudinalgroove 411. As shown, recess 413 extends perpendicular to inner surface412 to form a barb 14 (FIG. 19) that extends perpendicular to elongatebody 12 of suture 10, however, it is envisioned that recess 413 mayinstead extend from longitudinal groove 411 at various angles so as toform a barb 14 extending from elongate body 12 of suture 10 at variousangles. It is further envisioned that second nest half 420 may alsoinclude one or more recesses 423 (shown in phantom) for forming one ormore barbs 14. Either or both of first and second nest halves 410, 420are operably connected to a heating mechanism 458 for selectivelyheating at least portions of first and second nest halves 410, 420. Inone embodiment, heating mechanism 458 heats only the portions of firstand second nest halves 410, 420 corresponding to recesses 423.

The use of barb forming nest 400 will be now described with particularreference to FIGS. 17-19. Initially, a length of suture 10 is loadedwithin elongated passage 401 of nest 400. As seen, suture 10 includes adiameter larger then the diameter of elongated passage 401. Heatingmechanism 458 is then activated to heat either or both of first andsecond nest halves 410, 420. Heating of nest halves 410, 420 causessuture 10 to soften and/or melt. Approximation of first and second nesthalves 410, 420 towards each other, as indicated by arrows “F” (FIG.18), as suture 10 is melted, forces the melted material of suture 10into recess 413 to form barb 14. Once inner surfaces 412, 422 of firstand second nest halves 410, 420 are in contact, heating mechanism 458 isdeactivated and suture 10 is permitted to solidify. As with punch member156, first and second nest halves 410, 420 may include a heat sink (notshown) to facilitate cooling of suture 10. Once suture 10 has cooledsufficiently, first and second nest halves 410, 420 are approximatedaway from each other and suture 10 is removed. Suture 10 may then berepositioned within nest 400 and the process may be repeated. As withthe previously disclosed suture forming nests, it is envisioned thatbarb forming nest 400 may be configured to form barbs 14 along an entirelength of elongate body 12 of suture 10 simultaneously.

While the above description contains many specifics, these specificsshould not be construed as limitations on the scope of the disclosure,but merely as exemplifications of embodiments thereof. Those skilled inthe art will envision many other possibilities within the scope andspirit of the disclosure as defined by the claims appended hereto. Forexample, each of first and second nest halves 110, 120 may each includeboth openings and recesses. In this manner, radially offset barbs may beformed without moving suture 10 relative to the nest. A second punch mayalso be used with the nest to simultaneously form the second set ofbarbs. Alternatively, or in addition, openings and recesses may beformed in either or both of the top and bottom surfaces of the nesthalves to further permit forming of radially offset barbs without movingsuture 10.

The invention claimed is:
 1. A method of making a barbed suture, themethod comprising: providing a suture nest and a punch apparatusincluding at least one punch member, wherein the punch apparatus isconfigured for operable engagement with the suture nest and the suturenest defines at least one opening corresponding to the at least onepunch member and at least one recess opposite the at least one opening;loading a suture through the suture nest; heating the at least one punchmember; engaging a distal surface of the at least one punch member withthe suture by receiving the at least one punch member through the atleast one opening in the suture nest to displace a portion of the sutureinto the at least one recess to form a displaced portion of suture,wherein the displaced portion of suture remains integral with thesuture; and disengaging the punch member from the suture.
 2. The methodof claim 1, wherein the suture nest includes first and second suturenest halves.
 3. The method of claim 2, wherein the first suture nesthalf defines a first longitudinal groove.
 4. The method of claim 3,wherein the first suture nest half defines the at least one recess, theat least one recess being formed along the first longitudinal groove. 5.The method of claim 4, wherein the second suture nest half defines asecond longitudinal groove corresponding to the first longitudinalgroove.
 6. The method of claim 5, wherein the second suture nest halfdefines the at least one opening corresponding to the at least onerecess of the first suture nest half.
 7. The method of claim 5, whereinthe first and second longitudinal grooves form an elongate passagethrough the suture nest when the first and second suture nest halves areengaged.
 8. The method of claim 1, further including cooling the atleast one punch member prior to disengaging the distal surface of thepunch member from the suture.
 9. The method of claim 1, furtherincluding advancing the suture longitudinally relative to the suturenest.
 10. The method of claim 9, further including reengaging the distalsurface of the punch member with the suture.
 11. The method of claim 1,further including rotating the suture along a longitudinal axis.
 12. Themethod of claim 1, wherein engaging the distal surface of the at leastone punch member with the suture includes maintaining the distal surfacewith the suture until disengaging the punch member from the suture. 13.The method of claim 1, wherein the distal surface of the at least onepunch member is rounded.
 14. The method of claim 1, wherein engaging thedistal surface of the at least one punch member with the suture includesmoving the punch member perpendicular to the suture.
 15. A barbed sutureformed by the method of claim
 1. 16. A method of making a barbed suture,the method comprising: advancing at least one punch member through anopening in a suture nest into contact with a suture positioned in thesuture nest, the suture nest having a recess adjacent to the suturepositioned therein opposite the opening, wherein contact of the punchmember with the suture causes displacement of a portion of the sutureinto the recess in the suture nest, the displaced portion of the sutureremaining integral with the suture and forming a barb; and withdrawingthe at least one punch member from contact with the suture.
 17. Themethod of claim 16, further including advancing the suturelongitudinally relative to the suture nest and repeating the advancingand withdrawing steps.
 18. The method of claim 16, further includingrotating the suture along a longitudinal axis and repeating theadvancing and withdrawing steps.
 19. The method of claim 16, furtherincluding heating the at least one punch member.
 20. The method of claim16, further including ultrasonically oscillating the at least one punchmember.
 21. The method of claim 16, wherein advancing the at least onepunch member into contact with the suture includes contacting the suturewith a distal surface of the at least one punch member.
 22. The methodof claim 16, wherein advancing the at least one punch member intocontact with the suture includes moving the punch member perpendicularto the suture.